U.S. patent application number 15/752816 was filed with the patent office on 2018-08-23 for structure body and the manufacturing method.
This patent application is currently assigned to Kumi Kasei Co., Ltd.. The applicant listed for this patent is KUMI KASEI CO., LTD.. Invention is credited to Koichi ASHIMA, Etsuo OKAHARA.
Application Number | 20180236749 15/752816 |
Document ID | / |
Family ID | 58427424 |
Filed Date | 2018-08-23 |
United States Patent
Application |
20180236749 |
Kind Code |
A1 |
OKAHARA; Etsuo ; et
al. |
August 23, 2018 |
STRUCTURE BODY AND THE MANUFACTURING METHOD
Abstract
An object of the present invention is to provide a structure
body, which allows the obtaining of superior impact performance
while suppressing increases in thickness and weight of a plastic
plate and reducing cost, and a method for manufacturing that
structure body. Provided is a structure body (1) provided with a
structure (10) made of a metal or a thermosetting resin, a plastic
plate (14) attached to a surface (10a) of the structure (10) with
double-sided tape (12), and a non-foamed plastic sheet (A) having a
glass transition temperature of -20.degree. C. or lower arranged
between the structure (10) and the plastic plate (14). Also
provided is a method for manufacturing the structure body (1) that
includes arranging the plastic sheet (A) between the structure (10)
and the plastic plate (14) when attaching the plastic plate (14) to
the surface (10a) of the structure (10) with the double-side tape
(12).
Inventors: |
OKAHARA; Etsuo; (Haga-gun,
JP) ; ASHIMA; Koichi; (Haga-gun, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KUMI KASEI CO., LTD. |
Tokyo |
|
JP |
|
|
Assignee: |
Kumi Kasei Co., Ltd.
Tokyo
JP
|
Family ID: |
58427424 |
Appl. No.: |
15/752816 |
Filed: |
September 26, 2016 |
PCT Filed: |
September 26, 2016 |
PCT NO: |
PCT/JP2016/078187 |
371 Date: |
February 14, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 7/14 20130101; B32B
27/308 20130101; B32B 15/082 20130101; B32B 27/08 20130101; B32B
7/12 20130101; B32B 27/32 20130101; B32B 2307/558 20130101; B60Y
2304/01 20130101; B32B 37/0076 20130101; B60Y 2304/03 20130101;
B32B 2307/732 20130101; B32B 2319/00 20130101; B32B 15/20 20130101;
B60R 13/04 20130101; B60Y 2304/05 20130101; B32B 15/085 20130101;
B32B 2323/04 20130101; B32B 27/30 20130101; B32B 2250/44 20130101;
B32B 2327/06 20130101; B32B 2605/08 20130101; B62D 25/04 20130101;
B32B 27/20 20130101; B62D 29/005 20130101; B32B 2250/05 20130101;
B32B 2311/00 20130101; B32B 27/304 20130101; B32B 2307/4026
20130101; B32B 2309/105 20130101; B32B 15/09 20130101; B32B 15/06
20130101; B32B 25/08 20130101; B32B 7/05 20190101; B32B 27/365
20130101; B32B 37/182 20130101; B32B 15/08 20130101; B32B 2333/08
20130101; B32B 25/16 20130101; B62D 27/026 20130101; B32B 27/302
20130101; B32B 2311/24 20130101 |
International
Class: |
B32B 7/14 20060101
B32B007/14; B32B 15/06 20060101 B32B015/06; B32B 15/085 20060101
B32B015/085; B32B 15/20 20060101 B32B015/20; B32B 25/08 20060101
B32B025/08; B32B 25/16 20060101 B32B025/16; B32B 27/08 20060101
B32B027/08; B32B 27/30 20060101 B32B027/30; B32B 27/32 20060101
B32B027/32; B32B 37/00 20060101 B32B037/00; B32B 37/18 20060101
B32B037/18; B60R 13/04 20060101 B60R013/04; B62D 25/04 20060101
B62D025/04; B62D 29/00 20060101 B62D029/00; B62D 27/02 20060101
B62D027/02 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 29, 2015 |
JP |
2015-191348 |
Claims
1. A structure body provided with a structure made of a metal or a
thermosetting resin, a plastic plate attached to the surface of the
structure with double-sided tape, and either or both of a
non-foamed plastic sheet (A) having a glass transition temperature
of -20.degree. C. or lower and a non-foamed rubber sheet (B) having
a glass transition temperature of -20.degree. C. or lower arranged
between the structure and the plastic plate.
2. The structure body according to claim 1, wherein the plastic
plate is an acrylic resin plate.
3. The structure body according to according to claim 1, wherein
the plastic sheet (A) is a polyethylene sheet.
4. The structure body according to claim 1, wherein a laminate,
provided with a substrate composed of a plastic sheet or a thin
metal plate and a rubber sheet (B) composed of unvulcanized rubber
formed in the form of a sheet on the substrate, is attached to the
structure or the plastic plate between the structure and the
plastic plate.
5. The structure body according to according to claim 4, wherein
the laminate is a plastic tape.
6. The structure body according to claim 1, wherein the thickness
of the plastic sheet (A) is 0.01 mm to 0.4 mm.
7. The structure body according to claim 1, wherein the plastic
plate is an outer pillar of an automobile.
8. A method for manufacturing a structure body having a plastic
plate attached to the surface of a structure made of a metal or a
thermosetting resin with double-sided tape, wherein either or both
of a non-foamed plastic sheet (A) having a glass transition
temperature of -20.degree. C. or lower and a non-foamed rubber
sheet (B) having a glass transition temperature of -20.degree. C.
or lower are arranged between the structure and the plastic plate.
Description
TECHNICAL FIELD
[0001] The present invention relates to a structure body and the
manufacturing method.
[0002] The present application claims priority on the basis of
Japanese Patent Application. No. 2015-191348 filed in Japan on Sep.
29, 2015, the contents of which are incorporated herein by
reference.
BACKGROUND ART
[0003] Products in which the surface of a plastic plate molded from
ABS resin and the like is painted black color, which impart the
close visual quality as the front and rear window glass surfaces,
are frequently used as, for example, outer pillars mounted on the
outside of "B" pillar of automobile doors. However, such outer
pillars have problems such as an environmental load during painting
process, high defect rate, and higher product cost.
[0004] Therefore, the painting process has been eliminated in
recent years by using acrylic resin plates molded from polymethyl
methacrylate and the like for use as outer pillars. However, due to
the insufficient impact performance of acrylic resin plates, there
are problems in terms of practical use in applying these acrylic
resin plates as outer pillars as is. In particular, the problem of
poor impact performance at low temperatures is significant.
[0005] A method is known for improving the impact performance of
outer pillars that consists of two-color molding with ABS resin or
glass fiber filled ABS resin and acrylic resin to obtain a plastic
plate in which these components are laminated (Patent Documents 1
to 3). However, when the aforementioned plastic plate is used in an
outer pillar, there are problems that are disadvantageous in terms
of fuel consumption related to an increase in weight, as well as
problems resulting in impairment of the sense of unity appearance
with the window glass surface due to an increase in the amount of
protrusion of the outer pillar from the glass surface caused by an
increase in thickness. In addition, this is also disadvantageous in
terms of cost due to the need for a special equipment for two-color
molding.
PRIOR ART DOCUMENTS
Patent Documents
[0006] Patent Document 1: Published Japanese Translation No.
2014-527932 of PCT International Publication
[0007] Patent Document 2: Published Japanese Translation No.
2014-527933 of PCT International Publication
[0008] Patent Document 3: Published Japanese Translation No.
2014-527934 of PCT International Publication.
DISCLOSURE OF THE INVENTION
Problems to be Solved by the Invention
[0009] An object of the present invention is to provide a structure
body, which allows the obtaining of superior impact performance
without increases in thickness and weight of a plastic plate and
reducing cost, and a method for manufacturing that structure
body.
Means for Solving the Problems
[0010] The present invention has the configurations indicated
below.
[0011] [1] A structure body provided with a structure made of a
metal or a thermosetting resin, a plastic plate attached to the
surface of the structure with double-sided tape, and either or both
of a non-foamed plastic sheet (A) having a glass transition
temperature of -20.degree. C. or lower and a non-foamed rubber
sheet (B) having a glass transition temperature of -20.degree. C.
or lower arranged between the structure and the plastic plate.
[0012] [2] The structure body of [1], wherein the plastic plate is
an acrylic resin plate.
[0013] [3] The structure of [1] or [2], wherein the plastic sheet
(A) is a polyethylene sheet.
[0014] [4] The structure body of any of [1] to [3], wherein a
laminate, provided with a substrate composed of a plastic sheet or
a thin metal plate and a rubber sheet (B) composed of unvulcanized
rubber formed in shape of sheet on the substrate, is attached to
the structure or the plastic plate located between the structure
and the plastic plate.
[0015] [5] The structure body of [4], wherein the laminate is a
plastic tape.
[0016] [6] The structure body of any of [1] to [5], wherein the
thickness of the plastic sheet (A) is 0.01 mm to 0.4 mm.
[0017] [7] The structure body of any of [1] to [6], wherein the
plastic plate is an outer pillar of an automobile.
[0018] [8] A method for manufacturing a structure body having a
plastic plate attached to the surface of a structure made of a
metal or a thermosetting resin with double-sided tape, wherein
either or both of a non-foamed plastic sheet (A) having a glass
transition temperature of -20.degree. C. or lower and a non-foamed
rubber sheet (B) having a glass transition temperature of
-20.degree. C. or lower are arranged between the structure and the
plastic plate.
Effects of the Invention
[0019] The structure body of the present invention allows the
obtaining of superior impact performance while suppressing increase
in thickness and weight of a plastic plate and lower cost.
[0020] According to the method for manufacturing a structure body
of the present invention, a structure body is obtained that allows
the obtaining of superior impact performance while suppressing
increase in thickness and weight of a plastic plate and reducing
the cost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a cross-sectional view showing one example of the
structure body of the present invention.
[0022] FIG. 2 is a cross-sectional view showing another example of
the structure body of the present invention.
[0023] FIG. 3 is a cross-sectional view showing another example of
the structure body of the present invention.
[0024] FIG. 4 is a cross-sectional view showing another example of
the structure body of the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
[0025] Definitions of the following terms are applied throughout
the present description and claims.
[0026] A "plastic sheet" includes a plastic sheet obtained by
molding a resin into the form of a sheet by extrusion molding and
the like in addition to that having a resin-based adhesive material
formed in shape of sheet on the substrate.
[0027] A "rubber sheet" includes a plastic sheet obtained by
molding rubber into the form of a sheet by extrusion molding and
the like in addition to that having a rubber-based adhesive
material formed in shape of sheet on the substrate.
[0028] The "back side" of a plastic plate refers to the side of the
structure.
Structure Body
[0029] The structure body of the present invention is provided with
a structure made of a metal or a thermosetting resin, a plastic
plate attached to the surface of the structure with double-sided
tape, and either or both of a non-foamed plastic sheet (A) and a
non-foamed rubber sheet (B), which they will be subsequently
described, located between the structure and the plastic plate.
[0030] The double-sided tape is preferably attached to the
peripheral edge of the plastic plate from the viewpoint of
maximizing the area on where the plastic sheet (A) and the rubber
sheet (B) are located. Meanwhile, the double-sided tape is not
necessarily required to be attached over the entire circumference
along the peripheral edge of the plastic plate as far as the
plastic plate is strictly attached to the structure when the
plastic sheet (A) or rubber sheet (B) is located between the
plastic plate and the structure. For example, if the plastic plate
has long shape such as a rectangular shape, the double-sided tape
may be attached only at longer side of the peripheral edges of the
plastic plate.
[0031] The plastic sheet (A) and the rubber sheet (B) are
preferably attached to the structure or to the plastic plate.
Furthermore, the plastic sheet (A) and the rubber sheet (B) are not
required to be attached to neither the structure nor the plastic
plate when they are located between the structure and the plastic
plate.
[0032] Only one of either the plastic sheet (A) or the rubber sheet
(B) may be arranged between the structure and the plastic plate or
both may be arranged between the structure and the plastic plate.
In the case of using both the plastic sheet (A) and the rubber
sheet (B), the plastic sheet (A) and the rubber sheet (B) may be
arranged as a laminate.
[0033] In the case of using the plastic sheet (A), the plastic
sheet (A) may be arranged as a laminate consisting of a substrate
other than the rubber sheet (B) and the plastic sheet (A).
Similarly, in the case of using the rubber sheet (B), the rubber
sheet (B) may be arranged as a laminate consisting of a substrate
other than the plastic sheet (A) and the rubber sheet (B).
[0034] The following provides an explanation of examples of the
structure body of the present invention based on FIGS. 1 to 4.
[0035] As shown in FIG. 1, a structure body 1 is provided with a
structure 10, a plastic plate 14 attached to a surface 10a of the
structure 10 with a double-sided tape 12, and a plastic sheet (A)
16 arranged between the structure 10 and the plastic plate 14. The
double-sided tape 12 is attached to the peripheral edge of the
plastic plate 14. The plastic sheet (A) 16 is arranged to the
inside of the double-sided tape 12 on the surface 10a of the
structure 10 when viewed from overhead. The thickness of the
plastic sheet (A) 16 is less than the thickness of the double-sided
tape 12, and a space is formed between the plastic sheet (A) 16 and
the plastic plate 14.
[0036] As shown in FIG. 2, a structure body 2 is provided with the
structure 10, the plastic plate 14 attached to the surface 10a of
the structure 10 with the double-sided tape 12, and a rubber sheet
(B) 18 arranged between the structure 10 and the plastic plate 14.
The structure body 2 is the same as the structure body 1 with the
exception of being provided with the rubber sheet (B) 18 instead of
the plastic sheet (A) 16.
[0037] As shown in FIG. 3, a structure body 3 is provided with the
structure 10, the plastic plate 14 attached to the surface 10a of
the structure 10 with the double-sided tape 12, and a laminate 20
arranged between the structure 10 and the plastic plate 14. The
laminate 20 is a laminate consisting of a substrate 22 and the
plastic sheet (A) 16. The double-sided tape 12 is attached to the
peripheral edge of the plastic plate 14, and the laminate 20 is
attached to the inside of the double-sided tape 12 on the back side
of the plastic plate 14 so that the plastic sheet (A) 16 faces the
plastic plate 14. The thickness of the laminate 20 is less than the
thickness of the double-sided tape 12 and a space is formed between
the laminate 20 and the structure 10.
[0038] As shown in FIG. 4, a structure body 4 is provided with the
structure 10, the plastic plate 14 attached to the surface 10a of
the structure 10 with the double-sided tape 12, and a laminate 24
arranged between the structure 10 and the plastic plate 14. The
structure body 4 is the same as the structure body 3 with the
exception of being provided with the laminate 24 instead of the
laminate 20. The laminate 24 is a laminate consisting of a
substrate 26 and the rubber sheet (B) 18. The laminate 24 is
attached to the plastic plate 14 so that the rubber sheet (B) 16
faces the plastic plate 14.
Structure
[0039] The structure is only required to be that made of a metal or
a thermosetting resin, and examples thereof include the chassis of
an automobile or motorcycle, and the housing of a refrigerator.
[0040] There are no particular limitations on the shape or size of
the structure provided a plastic plate can be attached to the
surface thereof with double-sided tape.
Plastic Plate
[0041] The present invention is particularly effective in the case
the plastic plate is an outer pillar of an automobile. Furthermore,
the plastic plate is not limited to an outer pillar, but rather may
also be other areas of as automobile, for example, a front
grille.
[0042] There are no particular limitations on the resin that forms
the plastic plate, and examples thereof include acrylic resins such
as polymethyl methacrylate (PMMA), polystyrene, ABS resin and
polycarbonate resin. The present invention is more effective in the
case of using a plastic plate having low impact performance, such
as an acrylic resin plate or polystyrene plate. In addition, since
an acrylic resin plate is frequently used for the outer pillar, the
present invention is particularly effective in the case the plastic
plate is an acrylic resin plate.
[0043] The resin that forms the plastic plate may be only one type
of resin or two or more types of resin.
[0044] An additive such as a pigment, dye or anti-aging agent may
be incorporated in the resin that forms the plastic plate as
necessary.
[0045] The additive may be one or multiple types of additives.
[0046] The thickness of the plastic plate can be suitably set
corresponding to the application.
[0047] In the case the plastic plate is an outer pillar, the
thickness of the plastic plate is preferably between 1.0 mm to 3.5
mm and more preferably between 1.5 mm to 2.0 mm. If the thickness
of the plastic plate is 1.0 mm or more, simultaneous to ensuring a
level of rigidity required for practical use, superior impact
performance is easily obtained. If the thickness of the plastic
plate is 3.5 mm or less, the amount of protrusion of the outer
pillar from the glass surface is reduced, thereby improving the
sense of unity appearance with the glass surface.
Double-sided Tape
[0048] There are no particular limitations on the double-sided tape
and a known double-sided tape can be used. Examples of double-sided
tape include known double-sided tape used to attach to the outer
pillar of an automobile.
[0049] The thickness of the double-sided tape is preferably between
0.4 mm to 1.5 mm, and more preferably between 0.6 mm to 1.0 mm. If
the thickness of the double-sided tape is 1.5 mm or less,
impairment of the sense of unity appearance with the glass surface
and a decrease in cold impact performance can be avoided, and if
the thickness is 0.4 mm or more, pressure during adhesion can be
applied uniformly resulting in adequate adhesive strength.
Plastic Sheet (A)
[0050] The plastic sheet (A) is a non-foamed plastic sheet having a
glass transition temperature (Tg) of -20.degree. C. or lower.
[0051] The plastic sheet (A) having a Tg of -20.degree. C. enables
the plastic sheet (A) to demonstrate favorable cushioning in an
environment exceeding -20.degree. C. Consequently, damage to the
plastic plate can be inhibited by alleviating shock acting on the
plastic plate in an environment exceeding -20.degree. C. In
addition, since the resin (A) is not foamed, the plastic sheet (A)
is more resistant to local deformation in comparison with foamed
sheets. Consequently, when a shock force acts on the plastic plate,
local deformation that exceeds the breaking elongation is inhibited
from occurring in the plastic plate. On the basis thereof,
arranging the plastic sheet (A) between the plastic plate and
structure makes it possible to inhibit the occurrence of damage to
the plastic plate when shock acts on the plastic plate.
[0052] The Tg of the plastic sheet (A) is -20.degree. C. or lower,
preferably -30.degree. C. or lower, and more preferably -50.degree.
C. or lower. The lower the Tg of the plastic sheet (A), the greater
the degree to which damage to the plastic plate can be inhibited in
environments at lower temperatures.
[0053] Furthermore, Tg in the present invention refers to the
mid-point glass transition temperature as measured by differential
scanning calorimetry (DSC).
[0054] The plastic sheet (A) is only required to be a plastic sheet
having a Tg of -20.degree. C. or lower, and examples thereof
include a polyethylene sheet (Tg: -120.degree. C.) and a
polyoxymethylene sheet (Tg: -50.degree. C.). Among these, a
polyethylene sheet is preferable from the viewpoints of being
inexpensive and readily available as well as allowing the effect of
minimizing damage to the plastic plate to be easily obtained.
[0055] A sheet molded by a known method such as extrusion molding
can be used for the plastic sheet (A). Furthermore, that having an
adhesive material composed of a resin having a Tg of -20.degree. C.
or lower formed in the form of a sheet on a substrate may also be
used for the plastic sheet (A). Namely, a laminate (to also be
referred to laminate (.alpha.)) consisting of a substrate and the
plastic sheet (A), obtained by forming an adhesive material having
a Tg of -20.degree.C. or lower in the form of a sheet, may be used
for the plastic sheet (A).
[0056] Examples of the substrate in the laminate (.alpha.) include
the plastic sheet (A) composed of a molded sheet obtained by
extrusion molding and the like, a plastic sheet other than the
plastic sheet (A) (such as a soft vinyl chloride sheet), the rubber
sheet (B), a rubber sheet other than the rubber sheet (B), and a
thin metal plate.
[0057] In the case of using a thin metal plate for the substrate,
the laminate (.alpha.) is preferably arranged between the structure
and the plastic plate so that the plastic sheet (A) is facing the
plastic plate from the viewpoint of allowing the effect of
inhibiting damage to the plastic plate to be easily obtained.
[0058] The thickness of the plastic sheet (A) is preferably less
than the thickness of the double-sided tape. As a result, forces
acts more easily on the portion of the double-sided tape when
attaching the plastic plate to the structure, and it becomes easy
to securely fasten the plastic plate to the structure. In the case
of using the laminate (.alpha.), the thickness of the laminate
(.alpha.) is preferably less than the thickness of the double-sided
tape.
[0059] The thickness of the plastic sheet (A) is preferably between
0.01 mm to 0.4 mm, and more preferably between 0.02 mm to 0.2 mm,
within a range that is less than the thickness of the double-sided
tape. If the thickness of the resin sheet (A) is 0.01 mm or more,
the effect of minimizing damage to the plastic plate is easily
obtained. If the thickness of the plastic sheet (A) is 0.4 mm or
less, the plastic plate is easily attached to the structure.
[0060] The ratio of the thickness of the plastic sheet (A) to the
thickness of the double-sided tape is preferably 1.25% to 50% and
more preferably 2.5% to 25%. If the aforementioned ratio is 1.25%
or more, the effect of minimizing damage to the plastic plate is
easily obtained. If the aforementioned ratio is 50% or less, the
plastic plate is easily attached to the structure.
[0061] In the case of using the laminate (.alpha.), the ratio of
the thickness of the laminate (.alpha.) to the thickness of the
double-sided tape is preferably within the aforementioned
ranges.
[0062] In the case of arranging the plastic sheet (A) or the
laminate (.alpha.) between the structure and the plastic plate, the
proportion of the plastic sheet (A) that occupies the area of the
plastic plate when viewed from overhead is preferably 40% to 99%,
more preferably 50% to 90%, and even more preferably 60% to 90%. If
the proportion of the area of the plastic plate occupied by the
plastic sheet (A) is 40% or more, the effect of minimizing damage
to the plastic plate is easily obtained. If the proportion of the
area of the plastic plate occupied by the plastic sheet (A) is 99%
or less, a region on the plastic plate for attaching the
double-sided tape is easily secured, thereby making it easy to
securely attach the plastic plate to the structure with the
double-sided tape.
[0063] In the case of using the plastic sheet (A), the number of
plastic sheets (A) arranged between the structure and the plastic
plate is preferably 1, from the viewpoint of workability.
Furthermore, the number of plastic sheets (A) arranged between the
structure and the plastic plate may also be 2 or more.
Rubber Sheet (B)
[0064] The rubber sheet (B) is a non-foamed rubber sheet having a
glass transition temperature (Tg) of -20.degree. C. or lower.
[0065] As a result of the rubber sheet (B) having a Tg of
-20.degree. C. and not being foamed, the occurrence of damage to
the plastic plate is minimized when a shock force acts on the
plastic plate for the same reason as the plastic sheet (A).
[0066] Tg of the rubber sheet (B) is -20.degree. C. or lower,
preferably -30.degree. C. or lower, and more preferably -40.degree.
C. or lower. The lower the Tg of the rubber sheet (B), the greater
the degree to which damage to the plastic plate can be minimized in
environments at lower temperatures.
[0067] The rubber sheet (B) is only required to be a rubber sheet
having a Tg of -20.degree. C. or lower, and is preferably a rubber
sheet obtained by forming unvulcanized rubber having a Tg of
-20.degree. C. or lower into the form of a sheet on a substrate.
Namely, a laminate (to be referred to as laminate (.beta.))
consisting of a substrate and the rubber sheet (B), obtained by
forming unvulcanized rubber having a Tg of -20.degree. C. or lower
into the form of a sheet, may be used for the rubber sheet (B).
[0068] Examples of unvulcanized rubber include polyisoprene
rubber-based adhesive (Tg: -73.degree. C.) and polybutadiene rubber
(Tg: -90.degree. C.)
[0069] The substrate in the laminate (.beta.) is preferably a
plastic sheet or thin metal plate. The plastic sheet used for the
substrate may be the plastic sheet (A) or a plastic sheet other
than the plastic sheet (A) such as a soft vinyl chloride sheet. In
the case of using a thin metal plate for the substrate, the
laminate (.beta.) is preferably arranged between the structure and
the plastic plate so that the rubber sheet (B) faces the plastic
plate from the viewpoint of easily obtaining the effect of
minimizing damage to the plastic plate.
[0070] The laminate (.beta.) is preferably plastic tape.
[0071] Furthermore, the rubber sheet (B) may also be a molded sheet
obtained by molding rubber having a Tg of -20.degree. C. or lower
by extrusion molding and the like.
[0072] The thickness of the rubber sheet (B) is preferably less
than the thickness of the double-sided tape. As a result, force
easily acts on the portion of the double-sided tape when attaching
the plastic plate to the structure, and it becomes easy to securely
fasten the plastic plate to the structure. In the case of using the
laminate (.beta.), the thickness of the laminate (.beta.) is
preferably less than the thickness of the double-sided tape.
[0073] The thickness of the rubber sheet (B) is preferably 0.01 mm
to 0.4 mm, and more preferably 0.01 mm to 0.2 mm, within a range
that is less than the thickness of the double-sided tape. If the
thickness of the rubber sheet (B) is 0.01 mm or more, it becomes
easy to manufacture a sheet and the effect of minimizing damage to
the plastic plate is easily obtained. If the thickness of the
rubber sheet (B) is 0.4 mm or less, the plastic plate is easily
attached to the structure.
[0074] The ratio of the thickness of the rubber sheet (B) to the
thickness of the double-sided tape is preferably 1.25% to 50%, and
more preferably 1.25% to 25%. If the aforementioned ratio is 1.25%
or more, the effect of minimizing damage to the plastic plate is
easily obtained. If the aforementioned ratio is 50% or less, the
plastic plate is easily attached to the structure.
[0075] In the case of using the laminate (.beta.), the ratio of the
thickness of the laminate (.beta.) to the thickness of the
double-sided tape is preferably within the aforementioned.
ranges.
[0076] In the case of arranging the rubber sheet (B) or the
laminate (.beta.) between the structure and the plastic plate, the
proportion of the rubber sheet (B) that occupies the area of the
plastic plate when viewed from overhead is preferably 40% to 99%,
more preferably 50% to 90%, and even more preferably 60% to 90%. If
the proportion of the area of the plastic plate occupied by the
rubber sheet (B) is 40% or more, the effect of minimizing damage to
the plastic plate is easily obtained. If the proportion of the area
of the plastic plate occupied by the rubber sheet (B) is 99% or
less, a region on the plastic plate for attaching the double-sided
tape is easily secured, thereby making it easy to securely attach
the plastic plate to the structure with the double-sided tape.
[0077] In the case of using the rubber sheet (B), the number of
rubber sheets (B) arranged between the structure and the resin
plate is preferably 1 from the viewpoint of workability.
Furthermore, the number of rubber sheets (B) arranged between the
structure and the plastic plate may also be 2 or more.
[0078] In the structure body of the present invention as explained
above, arranging the plastic sheet (A) or the rubber sheet (B)
between the structure and the plastic plate prevents the plastic
plate from colliding with the structure when a shock acts on the
plastic plate. Damage to the resin plate is minimized due to
cushioning provided by the plastic sheet (A) or the rubber sheet
(B). Consequently, even in the case of a plastic plate composed of
acrylic resin or polystyrene that is inferior with respect to shock
resistance, the occurrence of damage to the plastic plate can be
minimized when a shock force acts, thereon without having to
laminate a resin (such as ABS resin) having a high impact
performance.
[0079] In addition, in the structure body of the present invention,
since it is not necessary to laminate a resin having a high impact
performance, even in the case of a plastic plate that uses a resin
having inferior impact performance, the plastic plate can be
prevented from becoming excessively thick or excessively heavy. In
addition, the structure body of the present invention is also
advantageous in terms of cost since special equipment for carrying
out two-color molding and the like is not required.
[0080] In addition, in the present invention, the plastic plate is
attached to the structure with double-sided tape. In applications
requiring a high level of adhesive strength such as the attachment
of an outer pillar of an automobile, it is necessary to use an
expensive adhesive material having very high adhesive strength.
Since double-sided tape is sufficient if it is attached to the
peripheral edge of the plastic plate, the structure body of the
present invention is also advantageous in terms of cost in
comparison with an aspect in which an adhesive material is coated
over the entire surface of the plastic sheet (A) or the rubber
sheet (B) and the plastic plate is attached to the structure with
the sheet interposed there between.
[0081] Furthermore, the structure body of the present invention is
not limited to the aforementioned structure bodies 1 to 4.
[0082] For example, the structure body of the present invention may
be a structure body in which the plastic sheet (A) or the rubber
sheet (B) is attached to the plastic plate. In addition, the
structure body of the present invention may be that in which the
laminate (.alpha.) or the laminate (.beta.) is attached to the
structure.
Method for Manufacturing Structure Body
[0083] The method for manufacturing a structure body of the present
invention is a method for manufacturing the previously described
structure body of the present invention.
[0084] In the method for manufacturing a structure body of the
present invention, either or both of the plastic sheet (A) and the
rubber sheet (B) are arranged between the structure and the plastic
plate when attaching the plastic plate to the surface of the
structure.
[0085] There are no particular limitations on the method used to
arrange the plastic sheet (A) and the rubber sheet (B) between the
structure and the plastic plate. For example, in the case of using
the plastic sheet (A) alone, the plastic sheet (A) may be attached
to the back side of the plastic plate, or the plastic sheet (A) may
be attached to the surface of the structure. This applies similarly
to the case of using the laminate (.alpha.) , the rubber sheet (B)
alone and the laminate (.beta.).
[0086] In addition, there are no particular limitations on the
method used to attach the plastic sheet (A) or the rubber sheet (B)
to the structure or plastic plate, and for example, a method may be
employed in which the plastic sheet (A) or the rubber sheet (B) is
attached using an adhesive material. In the case the plastic sheet
(A) or the rubber sheet (B) has adhesiveness, the plastic sheet (A)
or the rubber sheet (B) may be attached as is.
[0087] Furthermore, the plastic sheet (A) and the rubber sheet (B)
are not necessarily required to be attached to the structure or
plastic plate.
[0088] According to the method for manufacturing a structure body
of the present invention as explained above, since the plastic
sheet (A) or the rubber sheet (B) is arranged between the structure
and the plastic plate, impact performance of the resulting
structure body is improved and the occurrence of damage to the
plastic plate is minimized even if a shock acts on the plastic
plate.
EXAMPLES
[0089] Although the following provides a detailed explanation of
the present invention through examples thereof, the present
invention is not limited by the following descriptions.
Materials Used
[0090] Materials used in the present examples are as indicated
below.
Plastic Sheet (A)
[0091] A-1: Polyethylene sheet (thickness: 0.09 mm, Tg:
-120.degree.C.)
[0092] A-2: Polyethylene sheet (thickness: 0.02 mm, Tg:
-120.degree. C.)
Rubber Sheet (B)
[0093] B-1: Rubber sheet (thickness: 0.01 mm) obtained by forming a
polyisoprene-based adhesive material (Tg: -73.degree. C.) in the
form of a sheet on a substrate
Substrate
[0094] C-1: Soft vinyl chloride sheet (thickness: 0.14 mm)
[0095] C-2: Release paper (thickness: 0.11 mm)
Sheet (X)
[0096] X-1: Rubber sheet obtained by forming an acrylic-based
adhesive material (Tg: -15.degree. C.) into the form of a sheet on
a substrate
[0097] X-2: Polyethylene terephthalate sheet: (thickness: 0.02 mm,
Tg: 69.degree. C.)
[0098] X-3: Polypropylene sheet (thickness: 0.25 mm, Tg:
-18.degree. C.)
[0099] X-4 Nylon 6 sheet (thickness: 0.25 mm, Tg: 50.degree.
C.)
[0100] X-5: Polyethylene foam sheet: (trade name: "Miramat", JSP
Corp., thickness: 1 mm)
Plastic Plate
[0101] D-1: Acrylic resin plate obtained by molding polymethyl
methacrylate (trade name: "FT8", Daicel-Evonik Ltd.) into a thick
sheet having a thickness of 1.5 mm
[0102] D-2: Acrylic resin plate obtained by molding polymethyl
methacrylate (trade name: "FT8", Daicel-Evonik Ltd.) into a thick
sheet having a thickness of 2.0 mm
[0103] D-3: Polystyrene plate having a thickness of 2 mm
Falling Ball Test
[0104] The state of a plastic plate was confirmed visually when a
steel ball having a diameter of 63.5 mm and weight of 1 kg was
allowed to freely fall onto a structure body obtained in each of
the examples from directly overhead the plastic plate in an
environment at -30.degree. C., and evaluated according to the
criteria indicated below. The height at which the steel ball was
dropped during the falling ball test was 10 cm, 20 cm, 30 cm, 40 cm
or 50 cm.
[0105] A: No damage to the plastic plate observed
[0106] B: Damage to the plastic plate observed
Example 1
[0107] Plastic sheet A-1 was arranged on an aluminum plate having a
flat surface and thickness of 20 mm followed attaching the plastic
plate D-1 to the aluminum plate with double-sided tape having a
thickness of 0.8 mm so that the plastic sheet A-1 was interposed
between the aluminum plate and the plastic plate D-1 to obtain a
structure body. The interval between the double-sided tape having
the plastic sheet A-1 interposed there between was 70 mm.
Example 2
[0108] A structure body was obtained in the same manner as Example
1 with the exception of using plastic sheet A-2 instead of plastic
sheet A-1.
Example 3
[0109] Double-sided tape for office use having rubber sheet X-1
formed on substrate C-2 (trade name: "Nicetack", Nichiban Co.,
Ltd.) was attached to the back side of plastic plate D-2 followed
by peeling off substrate C-2 and attaching to plastic sheet A-1.
Next, the laminate was attached to an aluminum plate having a flat
surface and thickness of 20 mm with double-sided tape having a
thickness of 0.8 mm so that the rubber sheet X-1 and the plastic
sheet A-1 were interposed between the aluminum plate and plastic
plate D-2 to obtain a structure body.
Example 4
[0110] Plastic tape (Hokusetsu Corp.) having rubber sheet B-1
formed on substrate C-1 was attached to the back side of plastic
plate D-1. Next, this laminate was attached to an aluminum plate
having a flat surface and thickness of 20 mm with double-sided tape
having a thickness of 0.8 mm so that the rubber sheet B-1 and
substrate C-1 were interposed between the aluminum plate and the
plastic plate D-1 to obtain a substrate body.
Example 5
[0111] Plastic tape (Hokusetsu Corp.) having rubber sheet B-1
formed on substrate C-1 was attached to an aluminum plate having a
flat surface and thickness of 20 mm. Next, plastic plate D-1 was
attached with double-sided tape having a thickness of 0.8 mm so
that the substrate C-1 and rubber sheet B-1 were interposed between
the aluminum plate and the plastic plate D-1 to obtain a structure
body.
Example 6
[0112] A structure body was obtained in the same manner as Example
1 with the exception of using plastic plate D-3 instead of plastic
plate D-1 and using plastic sheet A-2 instead of plastic sheet
A-1.
Example 7
[0113] A structure body was obtained in the same manner as Example
4 with the exception of using plastic plate D-3 instead of plastic
plate D-1.
Comparative Example 1
[0114] A structure body was obtained in the same manner as Example
1 with the exception of not using plastic sheet A-1.
Comparative Example 2
[0115] A structure body was obtained in the same manner as Example
1 with the exception of not using plastic sheet A-1 and using
plastic plate D-2 instead of plastic plate D-1.
Comparative Example 3
[0116] A structure body was obtained in the same manner as Example
3 with the exception of attaching double-sided tape for office use
having rubber sheet X-1 formed on substrate C-2 (trade name:
"Nicetack", Nichiban Co., Ltd.) to the back side of plastic plate
D-2 followed by attaching plastic sheet A-1 without peeling off
substrate C-2.
Comparative Example 4
[0117] A structure body was obtained in the same manner as Example
1 with the exception of not using plastic sheet A-1 and attaching
plastic sheet X-2 to the back side of plastic plate D-2.
Comparative Example 5
[0118] A structure body was obtained in the same manner as Example
1 with the exception of not using plastic sheet A-1 and attaching
plastic sheet X-3 to the back side of plastic plate D-2.
Comparative Example 6
[0119] A structure body was obtained in the same manner as Example
1 with the exception of not using plastic sheet A-1 and attaching
plastic sheet X-4 to the back side of plastic plate D-2.
Comparative Example 7
[0120] A structure body was obtained in the same manner as Example
1 with the exception of using sheet X-5 instead of plastic sheet
A-1 and using plastic plate D-2 instead of plastic plate D-1.
Comparative Example 8
[0121] A structure body was obtained in the same manner as Example
1 with the exception of not using plastic sheet A-1 and using
plastic plate D-3 instead of plastic n plate D-1.
[0122] The configurations and evaluation results of the structure
bodies of the examples and comparative examples are shown in Table
1.
[0123] Furthermore, in Table 1, "PMMA" refers to polymethyl
methacrylate and "PS" refers to polystyrene. "X-1/A-2" means that
sheet X-1 and sheet A-2 are arranged in that order starting from
the plastic plate side, and this applies similarly to other
notations such as "B-1/C-1".
TABLE-US-00001 TABLE 1 Dropping Height in Plastic Plate Falling
Ball Test Thickness Cushioning (cm) Type Material (mm) Material 10
20 30 40 50 Example 1 D-1 PMMA 1.5 A-1 A A A A A Example 2 D-1 PMMA
1.5 A-2 A A A A A Example 3 D-2 PMMA 2 X-1/A-2 A A A A B Example 4
D-1 PMMA 1.5 B-1/C-1 A A A A A Example 5 D-1 PMMA 1.5 C-1/B-1 A A A
A A Example 6 D-3 PS 2 A-2 A A A B B Example 7 D-3 PS 2 C-1/B-1 A A
A B B Comp. Ex. 1 D-1 PMMA 1.5 None B B B B B Comp. Ex. 2 D-2 PMMA
2 None B B B B B Comp. Ex. 3 D-2 PMMA 2 X-1/C-2 B B B B B Comp. Ex.
4 D-2 PMMA 2 X-2 B B B B B Comp. Ex. 5 D-2 PMMA 2 X-3 B B B B B
Comp. Ex. 6 D-2 PMMA 2 X-4 B B B B B Comp. Ex. 7 D-2 PMMA 2 X-5 B B
B B B Comp. Ex. 8 D-3 PS 2 None B B B B B
[0124] As shown in Table 1, in Examples 1 to 7, in which the
plastic sheet (A) or the rubber sheet (B) is arranged between the
plastic plate and an aluminum plate, the plastic plate was observed
to not be damaged even if the steel ball was dropped from a height
of 30 cm, thereby demonstrating superior impact performance.
[0125] On the other hand, in Comparative Examples 1, 2 and 8, in
which nothing was positioned between the plastic plate and aluminum
plate, and in Comparative Examples 3 to 6, in which a sheet having
a Tg of higher than -20.degree. C. was arranged between the plastic
plate and aluminum plate, damage was observed in the plastic plate
even when the steel ball was dropped from a height of 10 cm. In
addition, in Comparative Example 7 as well, in which sheet X-5
(polyethylene foam sheet) was arranged between the plastic plate
and aluminum plate, damage was observed in the plastic plate even
when the steel ball was dropped from a height of 10 cm.
[0126] One of the factors behind the improved impact performance
observed in Examples 1 to 7 is thought to be the contribution of
the cushioning properties of the plastic sheet (A) and the rubber
sheet (B).
[0127] In addition, the cause of the failure of improvement of
impact performance in the case of using the foam sheet of
Comparative Example 7 is thought to be as indicated below.
[0128] Although foam sheets demonstrate cushioning, they are easily
deformed as a result of being locally compressed when subjected to
pressure. Consequently, damage to the plastic plate is thought to
have occurred as a result of being unable to completely prevent
local deformation of the plastic plate when the steel ball was
dropped thereon. On the basis thereof, the use of non-foamed
plastic sheet (A) and rubber sheet (B) to enable prevention of
local deformation of the plastic plate is thought to be a factor
behind the improvement of impact performance.
INDUSTRIAL APPLICABILITY
[0129] The present invention is able to provide a structure body
that allows the obtaining of superior impact performance while
suppressing increases in thickness and weight of a plastic plate
and reducing cost. According to the method for manufacturing a
structure body of the present invention, a structure body is
obtained that allows the obtaining of superior impact performance
while suppressing increases in thickness and weight of a plastic
plate and reducing cost.
BRIEF DESCRIPTION OF THE REFERENCE SYMBOLS
[0130] 1,2,3,4 Structure body
[0131] 10 Structure
[0132] 12 Double-sided tape
[0133] 14 Plastic plate
[0134] 16 Plastic sheet (A)
[0135] 18 Rubber sheet (B)
[0136] 20,24 Laminate
[0137] 22,26 Substrate
* * * * *